Earpiece and manufacturing method and customization method of the earpiece

Abstract

The disclosure relates to an earpiece configured to be at least partially inserted into an ear and comprising a core comprising a material that during insertion of the earpiece into the ear is deformable above a transition temperature and non-deformable below the transition temperature. The disclosure also relates to a method of manufacturing the earpiece. The disclosure further relates to a method of customizing the earpiece.

The invention claimed is: 
     
       1. An earpiece configured to be at least partially inserted into an ear, the earpiece comprising:
 a core comprising a material that during insertion of the earpiece into the ear is deformable above a transition temperature and non-deformable below the transition temperature, 
 wherein:
 a sleeve at least partially encloses the core; 
 the sleeve has elastic properties selected such that the core conforms to a shape of the sleeve above the transition temperature and the core retains the sleeve in the shape below the transition temperature; 
 the core has an inner surface surrounding a cavity configured for receiving a component of a hearing device; 
 the sleeve at least partially encloses the core at the inner surface such that the cavity is delimited by a portion of the sleeve adjoining the core at the inner surface; 
 the core comprises a plurality of core sections extending in an axial direction of the cavity, two adjacent core sections included in the plurality of core sections having a recess between each other in a circumferential direction of the inner surface surrounding the cavity; and 
 a protrusion formed in the sleeve is provided inside the recess. 
 
 
     
     
       2. The earpiece according to  claim 1 , wherein the elastic properties are selected such that the sleeve comprises an original shape and that at least above the transition temperature:
 the sleeve is deformable from the original shape to a deformed shape during insertion of the earpiece into the ear, and 
 the sleeve returns to the original shape when no force is exerted on the sleeve. 
 
     
     
       3. The earpiece according to  claim 1 , wherein:
 the core has an outer surface that faces the sleeve; and 
 the sleeve at least partially encloses the outer surface of the core such that a portion of an outer surface of the sleeve forms a contact surface for contacting the ear. 
 
     
     
       4. The earpiece according to  claim 1 , wherein the sleeve comprises a material selected from a class which includes silicone, an elastomer, polyurethane, and compositions thereof. 
     
     
       5. The earpiece according to  claim 1 , wherein the cavity forms a bore at an end of the earpiece, the bore configured to be connected to the component of the hearing device. 
     
     
       6. The earpiece according to  claim 5 , wherein the bore is provided with a connector for the component, the connector configured to connect the earpiece with the component. 
     
     
       7. The earpiece according to  claim 1 , wherein, the sleeve has a hardness parameter in a range between 20 Shore A and 90 Shore A. 
     
     
       8. The earpiece according to  claim 1 , wherein the sleeve forms a wall having a thickness in a range of at least 0.1 mm and at most 3.5 mm. 
     
     
       9. The earpiece according to  claim 1 , wherein the core comprises a thermoplastic polymer. 
     
     
       10. The earpiece according to  claim 9 , wherein the thermoplastic polymer is selected from a class which includes one or more of polycaprolactone, poly(1,4-butylene adipate), polyethylene, ethylene-vinylacetate-copolymer, or polylactide. 
     
     
       11. The earpiece according to  claim 1 , wherein an original shape of the sleeve comprises a shape of at least one of an open-ended sleeve, a dome, or a preformed earmold. 
     
     
       12. The earpiece according to  claim 1 , wherein a stiffening member is provided in the earpiece, the stiffening member adjoining the sleeve and configured to bias against forces exerted on the earpiece upon insertion of the earpiece into the ear. 
     
     
       13. A method of manufacturing the earpiece according to  claim 1 , the method comprising providing the core, wherein the providing of the core includes providing the sleeve on the core such that the sleeve at least partially encloses the core. 
     
     
       14. The method according to  claim 13 , wherein the core is provided by injection molding. 
     
     
       15. The method according to  claim 14 , wherein the core is molded onto a connector of the earpiece. 
     
     
       16. The method according to  claim 13 , wherein the sleeve is provided on the core by at least one of injection molding, three dimensional printing, compression molding, dipping, manual coating, or spraying the sleeve onto the core. 
     
     
       17. The earpiece according to  claim 1 , wherein the recess is provided as a through hole from an outer surface to the inner surface of the core. 
     
     
       18. A method of customizing an earpiece to an ear of a user, the earpiece comprising a core comprising a material that during insertion of the earpiece into the ear is deformable above a transition temperature and non-deformable below the transition temperature, wherein a sleeve at least partially encloses the core, and the sleeve has elastic properties selected such that the core conforms to a shape of the sleeve above the transition temperature and the core retains the sleeve in the shape below the transition temperature, the method comprising:
 heating the earpiece above the transition temperature of the core such that the core is provided in a deformable condition, inserting the earpiece at least partially into the ear such that the sleeve is contacting the ear and a shape of the sleeve is deformed by the ear, and cooling the earpiece below the transition temperature inside the ear such that the core is provided in a non-deformable condition and the sleeve is retained in the shape by the core.